Means for molding shoe soles



May 20, 1969 1 3.13. DUBNER 4 5 MEANS FOR MOLDING SHOE SOLES Filed Dec; 21. 1966 Sheet y 20, 1969 B. B. DUBNER MEANS FOR MOLDING SHOE SOLES Sheet Filed Dec- 21. 1966 May 20, 1969 B. B.. DUBNER I 'MEANS FOR MOLDING SHOE SOLES Filed Dec. 21. 1966 3,444,586 Patented May 20, 1969 3,444,586 MEANS FOR MOLDING SHOE SOLES Benjamin B. Dubner, 229-02 Merrick Road, Laurelton, N.Y. Filed Dec. 21, 1966, Ser. No. 603,465 Int. Cl. B29d 31/00 US. Cl. 185.1 3 Claims This invention relates generally to the field of custom fitted shoes, and more particularly to an improved means for accomplishing same.

Modern living demands unnatural walking on hard fiat surfaces in shoes manufactured upon lasts normally contoured to an average foot, the lasts being distorted by considerations of style. Experience has shown that foot comfort can be achieved only when a foot is disposed in a shoe which properly fits and supports it.

Because of the many variables in feet, as well as shoe shapes of the same size, it has been estimated that approximately 70% of shoes users are fitted so poorly that the entire body weight is supported on two small areas of the foot causing discomfort, tired feet, pain and deformity.

It is known in the art to adjust the shoe to the individual foot on a mass scale, but previous efforts have been invariably unscientific in approach, relatively expensive, and time consuming to make. More seriously, they have been ineffective.

Among the prior art devices, the most well known is the arch support based in concept on the erroneous popular belief that comfort may be achieved by supporting the long arch of the foot. Actually, the long internal arch of the foot is not meant to come into contact with the ground to support weight directly. Actually, the Tarsal bones are squarish in configuration, and very rough for ligamentous attachments. Any substantial pressure here is usually uncomfortable and/or painful. Most so called supports do not reach this area, and are therefore wearable. In those cases where they do reach the area, they can be comfortably worn only after the support is broken in, that is to say actually broken down. Very often the shank of the shoe is also damaged in this process.

Any beneficial elfect that may be achieved is due to the incidental support at the front and back areas of the arched support where the area just behind the heads of the Metatarsal bones, and the area just anterior to the dependant part of the heel bone are smooth enough to accept pressure, and thus distribute the wegiht of the body over a large area. These areas are usually over parts of the shoe in direct contact with the ground, and therefore do not break down the shoe and lose its supported action.

Recognizing the above facts, Metatarsal pads have been used for a long time to fill in the area just behind the Metatarsal heads. Practice, unfortunately, is very far from theory, since it is extremely diflicult to apply the pads in the proper place. A difference of Azth inch forward or behind the proper place makes them either painful or ineffective. The only way to properly place a pad is to take a mark from the bare foot onto the shoe, and even where this is done, there are many other variables to contend with, such as flat feet, thin feet, variable shape and density of the pad, etc.

Mechanical Metatarsal pads so far have only attempted to fill in the area between the shank of the shoe and the foot, but, as they do not attempt to place the entire appliance in its proper position behind the Metatarsal heads, the position of which may vary as much as an inch from one foot to another with the same shoe size, the use of such pads is even less effective than the procedure described hereinabove.

Other prior art attempts, include the use of the Levy Mould which is designed to fill in all the concavities on the bottom of the foot. The device is made over a plaster cast of the foot, a fact which causes the process to lose a positive pressure necessary to compensate for tissue compressa'bility, and corrective action in the useful areas. The process also requires a wider shoe limited in style, in order to be able to accept such a mold, come of the good features of which are often ground away in the process of fitting the mold to the shoe. The desirable features of such a mold, mainly the crest which rises under the middle three toes to help distribute a body weight on the foot, very often are too high to be walked upon comfortably, as is the rise around the periphery of the heel.

To compensate for this, attempts have been made to form the molds within the shoe, placing the molding material suitably encapsulated in a large envelope, after which the foot is put into the shoe, during which process much of the material is pushed into the front of the shoe, after which the patient or customer walks about for approximately half an hour until the mold has set sufficiently to retain its imparted shape. The mold is then removed to cure for a week, after which it may be covered, ready for insertion within the shoe. Although this type of mold is constructed to be moved from one shoe to another, it really never fits another shoe as well as it does the one in which it was formed.

It is therefore among the principal assets of the present invention to provide an improved means for molding shoes for the foot, in which the above mentioned disadvantages and difficulties have been substantially eliminated.

Another object of the invention lies in the provision of an improved means for molding a shoe to the foot in critical areas, namely, the above mentioned crest area, the Metatarsal area, the heel area immediately forward of the heel, and the periphery of the heel.

Another object of the inveniton lies in the provision of means for molding a shoe to a foot both statically and dynamically within a few minutes, the means being such that it can be used by the average shoe clerk at the time of the sale of the shoe, in a neat, clean, and inexpensive manner.

Yet another object of the invention lies in the provision of a shoe construction incorporating a quick setting material injected through a unique opening and closing device fitted in the shank of a shoe, which allows the material to flow into the above mentioned four separate areas that are prepared to receive it in selected sequence.

Still another object of the invention lies in the provision of a novel opening and closing device used in conjunction with a material-injecting gun tip which may be used with a variety of injecting devices already known in the art.

A feature of the invention lies in the fact that the in ventive means may be employed in conjunction with a wide variety of types of shoes without substantial modification.

These objects and features, as well as other incidental ends and advantages, will more fully appear in the progress of the following disclosure, and be pointed out in the appended claims.

In the drawing, to which reference will be made in the specification, similar reference characters have been employed to designate corresponding parts throughout the several views.

FIGURE 1 is a longitudinal central section view of an embodiment of the invention.

FIGURE 2 is a plan view of the embodiment with the upper portion removed for purposes of clarity.

FIGURE 3 is a view in perspective corresponding to that seen in FIGURE 2.

FIGURE 4 is a longitudinal central sectional view as seen from the plane 44 in FIGURE 5.

FIGURE 5 is a planned view corresponding to that in FIGURE 2 but showing the sock lining elements thereof in position.

FIGURE 6 is a side elevational view somewhat schematic in nature of a means for injecting moldable material into a shoe.

FIGURE 7 is an enlarged fragmentary sectional view seen from the plane 77 in FIGURE 6.

FIGURE 8 is an exploded view in perspective corresponding to the structure as seen in FIGURE 7.

FIGURE 9 is a fragmentary sectional view as seen from the plane 9-9 in FIGURE 8.

FIGURE 10 is a schematic sectional view showing a second embodiment of the invention.

FIGURE 11 is a schematic plan view as seen from the upper portion of FIGURE 10.

FIGURE 12 is a fragmentary view in perspective corresponding to the upper central portion of FIGURE 11.

FIGURE 13 is a phantom schematic view showing the interconnection of air hoses for the melting of moldable material.

FIGURE 14 is a view in perspective showing one end of an air hose used in conjunction with the second embodiment.

In accordance with the invention, there is illustrated in FIGURE 1 in the drawing a shoe, generally indicated by reference character 10 of conventional construction, including an uppper flexible portion 11, a sole 12, which may be laminated, and a heel 13, a sock lining 14, which may be laminated of several layers of thickness, and covered by textile material is disposed above the sole 12, and interconnected at the peripheral edges thereof as will more fully appear hereinafter. The shank 15 may be of conventional construction, but is provided with an opening 16 for the injection of a molding material.

In FIGURE 5 in the drawing, the sock lining 14 is bounded by a peripheral edge 17, a forward portion 18 which is interconnected adjacent to the peripheral edge 19 of an insole 20. The rearward portion 21 thereof is interconnected above the rear portion 22 of the edge 19 of the insole 20, to provide a heat barrier protecting the wearer.

Referring to FIGURE 3, the sole 12 is inlet to form a forward recess 23 (to form a toe crust support), the recess being interconnected by a channel 24 to the opening 16. Disposed adjacently recess 23 is a Metatarsal recess 25 of somewhat larger dimensions, interconnected by a short channel 26 to the opening 16. A forward heel recess 27 is disposed, inwardly of the center line of the shoe, and interconnected by a feed channel 28 in a similar manner. A peripheral heel recess 29 is of generally elongated configuration, and interconnected by a channel 30. It will be obsreved from FIGURE 2 in the drawing at spaced intervals, the channels 24 and 30 are positioned 180 degrees from each other, and the channels 26 and 28 are also coaxially arranged. Positioned within the opening 16, and axially aligned therewith is an outer ring member 31 having opening '16, and axially aligned therewith is an outer ring member 31 having openings 32, 33, 34 and 35.

Referring to FIGURES 2 and 3, the recess 23 accommodates a molding material retaining bag 36 interconnected by a flat tube 37 in the channel 24 to the opening 32. In a similar manner, the recess 25 accommodates a bag 38 communicating with a tube 39 connected to the opening 33. Opening 34 communicates fluid into a bag 40, positioned within the recess 27 through a tube 41, and 'a bag 42, positioned within the recess 29 is fed by a flat tube 43 from the opening 35.

Referring to FIGURE 4, the sock lining 14 is provided with an opening 46 in the area of the recess 23 which is tfilled by a leather insert 47, to allow adequate accumulation of molding material at that point. The lining 14 is otherwise interconnected by glue means (not shown) at the center 48 of the heel, and a forward point 49 disposed between the recesses 23 and 25.

The shoe 10 is provided with injection means 50, including the above mentioned ring member 31 maintained in position by upper flange 52 extending outwardly from a cylindrical portion 53 having the above mentioned openings 32-35 inclusive. A locking flange 53a cooperates with a notch surface 81 as will more fully appear to maintain the means 50 in engagement with the shoe during injection. Arranged for coaxial relative rotation is a second ring 55: held in position by a flange 56, and including a cylindrical sleeve 57. The sleeve 57 is provided with a noncircular bore 58 including radially extending recesses 59, the bore 58 communicating with a pair of aligned bores 60 selectively positionable to feed the tubes 37 and 43, alternately with the tubes 39 and 41.

Engageable within the second ring 55 is an injection means 61, best seen in FIGURE 6 in the drawing, the means 61 including an injection gun 62 having an interconnecting nozzle or tip 63. A pistol grip handle element 64 conducts a power cord 65 from a source of electrical energy (not shown) to a heating element 66 surrounding a recess 67 containing a moldable fluid (not shown). The recess 67 communicates through a connecting channel 68 to the nozzle or tip 63. A plunger 69 is actuated by a reciprocating member 70, in turn resiliently urged by a spring 71 to urge fluid from the recess 67 to the tip 63. The reciprocating member 70 includes a manually engageable member 72 mounted on a first shaft 73 splined to a second shaft 74, to the opposite end 75 of which mounts a toothed segment 76 meshing with a segment ring gear 77 on a rotatable member 78. The member 78 surrounds the tip 63, and includes a tubular portion 79 bounded by an outer cylindrical surface 80 and a notched surface 81. Disposed radially of the centrally positioned bore 82 are projections 83 aligned with corresponding projections 84 on a ring-like member '85, both the projections 83 and '84 mating with the recesses 59 in the sleeve 57. A wall '88 prevents the escape of most of the material other than through the radially arranged openings 89 aligned with the tip 63.

At the time of use, the gun 62 is supplied with power through the cord 65 whereby the heating element 66 will warm the molding material (not shown) disposed therein to a flowable state. The gun 62 inclduing the tip 63 and members 85 and 78 is engaged with the sleeve 57, so that motion imparted to rotatable member 78 is transmitted to the sleeve 57, and thence to the member 85. Rotational motion first establishes communication between the tip 63 and the bags 38 and 40, while the wearer is wearing the shoe, and in seated position. When these areas are filled, the above-mentioned members are rotated to a position wherein all of the openings are closed, and the injected liquid is given an opportunity to cool and set. The members are again further turned to establish communication 'with the bags 36 and 42 and the molding material is then flowed to fill the same, following which the sleeve 57 is positioned to close the openings 32 and 35, and the gun 62 is disconnected from the shoe.

The material in the bags 36 and 42 is then molded by tflge wearer walking about in the shoe as the material solid- 1 es.

Thus, the Metatarsal and anterior heel areas are molded in a static condition while the wearer is in a seated condition, and the more critical crest and peripheral heel areas are molded dynamically as the wearer walks in the shoe. It may be noted that there is no filling under the Tarsus and center of arch areas for the reason that the bags and tubes specifically do not enter into these areas. By following this procedure, there is no area that needs to be broken down when the wearer commences wearing the shoe, and the shoe will have comfortable support from the time of the first wearing thereof.

Turning now to the second embodiment of the invention, as illustrated in FIGURES through 14, in elusive, the construction illustrated is suitable where a less costly construction is desired and it is preferable to eliminate the building into the shoe outsole the means for injecting the molding material. In the case of the second embodiment, the molding material is positioned Within an envelope, the envelope in turn being positioned above the sole, and heating means softens the molding material in situ.

Thus, the shoe, generally indicated by reference character 110 may include an outer sole 111, a heel element 112, as well as an inner sole or sock lining 113. In the interstice 114 between the outer sole 111 and the sock lining 113, generally indicated by reference character 114, there is disposed a first bag element 115 including a lower lamina 116 and an upper lamina 117. The laminae 116 117 are heat-sealed at the peripheral edge 118 thereof and encloses a shaped paraffin block 119.

A second bag element 120 overlies the first bag element 115' and includes upper and lower laminae 121 and 122 similarly sealed at the peripheral edges. As best seen in FIGURES 10 and 11, the second bag element 120 may be slightly smaller than the first bag element, and is self-adhered in the area indicated by reference character 125 to prevent ballooning. Orifices 124 and 124a are adapted to be interconnected with an inlet tube 126 and an outlet tube 127, whereby heated and cooled air may be continuously circulated through the second bag element, as seen in FIGURE 13.

During use, the center portion 129 will swell with the injection of air blown into the second bag element, causing it to balloon out until it comes against the foot 130 of the user and the upper surface of the first bag element 115. The hot air will heat and soften the paraffin block 119, and the ballooning action will force the partflin forward and backward into the empty parts of the first bag elemerit to fill any empty spaces between the foot and the shoe. The partially adhered area 125 will maintain the heat to keep the parafiin liquid as long as necessary, following which cool air is blown into the bag to hasten the setting of the paraffin.

Once the desired configuration has been obtained, the

second bag element may remain in place, or be removed. In the case where the same is to remain in place, it will be provided with grommetted openings at 124 and 124a to receive expanding tipped nozzles 131 (see FIG- URE 14) which will expand under pressure to prevent premature disconnection. The space occupied by the nozzles is accommodated by the depressed area 132 in the paraflin block 119, as best seen in FIGURE 10.

I wish it to be understood that I do not consider the invention limited to the precise details of structure shown and set forth in this specification, for obvious modifications will occur to those skilled in the art to which the invention pertains.

I claim:

1. An apparatus for molding a shoe sole comprising a sole element having a plurality of recesses corresponding in location with respect to the foot of a wearer to the toe crest immediately forward of the Metatarsal heads, the Metatarsal area, the area forward of the heel, and the periphery of the heel; means for maintaining a molding material in each of said recesses, and means for injecting a molding material in selective manner into each of said recess.

2. Structure in accordance with claim 1 in which th last mentioned means includes an opening penetrating said sole element, valving means disposed in said opening, and means for establishing communication between the said opening and said recesses.

3. Structure in accordance with claim 2 wherein said means for injecting a molding material is selectively engageable with said sole element.

References Cited UNITED STATES PATENTS 2,082,451 6/1937 Kilvahan et al 185.1 2,600,507 6/1952 Leahy et al. 2,874,392 2/1959 Campione 18-175 X 2,924,849 2/1960 Buchman 18-5.1 3,175,249 3/1965 Terreira.

J. HOWARD FLINT, JR., Primary Examiner.

US. Cl. X.R. 18-30 

1. AN APPARATUS FOR MOLDING A SHOE SOLE COMPRISING A SOLE ELEMENT HAVING A PLURALITY OF RECESSES CORRESPONDING IN LOCATION WITH RESPECT TO THE FEET OF A WEARER TO THE TOE CREST IMMEDIATELY FORWARD OF THE METATARSAL HEADS, THE METATARSAL AREA, THE AREA FOWARD OF THE HEEL, AND THE PERIPHERY OF THE HEEL; MEANS FOR MAINTIANING A MOLDING MATERIAL IN EACH OF SAID RECESSES, AND MEANS FOR INJECTING A MOLDING MATERIAL IN SELECTIVE MANNER INTO EACH OF SAID RECESS. 